Textile Sizing
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2 PROPERTIES OF FIBERS AND YARNS 2.1 INTRODUCTION The utilization and serviceability of textile materials, other than industrial or technical textiles, are determined by their physical and mechanical properties, which include softness, pliability, good handle, feel, and drape [1]. The pliabil- ity of a textile structure is attributed to the fact that it is composed of a number of individual elements, commonly referred to as yarns. These yarns are made up of either staple or filament fibers, having sufficient degree of freedom of movement within the fabric structure without causing distortions. The softness and pliability of textile fabrics are due to this freedom of movement of constitu- tional elements, i.e., the fibers and yarns. The yarns are generally formed by twisting a bundle of fibers together. Though the process of twisting generates transverse pressures to prevent slippage of fibers, especially in staple yarns under axial tension, the yarns still retain flexibility because of the inherent flexibility of textile fibers. Obviously, it implies that the properties of textile structures will depend substantially upon the properties of fibers, which are the true building units. The process of woven fabric manufacturing is neither simple nor accom- plished in one step. The conversion of raw materials (fibers) into finished products (fabrics) involves many different steps, broadly categorized as spin- ning of a yarn, weaving of a fabric, and finishing. Each of these steps in turn involves many intermediate processes to perform well-defined specific functions. The process of spinning staple yarns involves preparatory steps such Copyright © 2004 Marcel Dekker, Inc. Properties of Fibers and Yarns 19 as opening and cleaning of cotton fiber stock, or only opening for synthetic fibers, optimal blending of different fibers, carding, combing, drawing, and twist insertion. The process of weaving is preceded by preparatory steps of winding, warping, and slashing (more commonly known as sizing). The processes of spinning and weaving have undergone many develop- ments due to the proliferation of high-speed production technologies. In to- day’s market-based economy, the scale and speed of spinning and weaving operations are decisive factors. The quality of yarns and warp preparation processes, such as winding, warping, and sizing, are prerequisites for the suc- cess of newer high-speed weaving technologies. To keep pace with changing weaving technologies, the process of sizing and ingredients used for sizing have also changed. The success of the sizing operation, on which the success of weaving and to some extent the quality of woven fabric are based, is influ- enced by the quality and properties of the warp yarns. Before discussing the process of sizing it is important to know the properties of fibers used in the making of various types of yarns. The fiber type and characteristics have a profound influence on the geometry and other properties of staple yarns spun on various spinning systems [2]. The mechanical behavior of staple yarns is strongly dependent on the properties of the constituent fibers and their disposi- tion in the body of the yarn [2]. 2.2 FIBERS A staple fiber is a long, thin, and flexible material, very similar to human hair, having macroscopic dimension along its length but microscopic transverse dimension [1,3]. The ratio of length to thickness of fibers, defined as slender- ness ratio, is usually of the order of 1000 and above [3,4]. The inherent attri- butes of flexibility, fineness, and a high length-to-width ratio of fibers make them suitable for producing soft and flexible fabrics. The ease of converting fabrics into garment greatly depends upon the ability of the fabrics to conform to three-dimensional shapes such as the human body. Table 2.1 illustrates the typical dimensions of some natural fibers. Besides slenderness ratio, the other most important property of textile fibers is elasticity. The breaking extension of an ideal textile fiber should be between 5 to 50% depending upon the actual end-use application [5]. The extensibilities of glass and crystalline solids are below 5%, and those of rubbers are above 50%, which makes them very difficult to process during subsequent spinning and weaving operations. These fibrous materials having suitable ex- tensibility for successful textile processing are all partially oriented, partially Copyright © 2004 Marcel Dekker, Inc. 20 Chapter 2 Table 2.1 Length-to-Diameter Ratios of Natural Textile Fibers Fiber Typical length (mm) Typical diameter (m) Slenderness ratio Cotton 25 17 1500 Wool 75 25 3000 Cashmere 40 18 2200 Mohair 55 28 1900 Flax 25 20 1250 Jute 2.5 15 170 Hemp 40 25 1600 Ramie 150 50 3000 Source: Refs. 4 and 5. crystalline (usually linear polymers), and similar to some naturally available cellulosic and protein fibers. 2.2.1 Classification of Textile Fibers Textile fibers are broadly classified into two major groups: (1) natural and (2) manmade, depending upon the nature of their origin. Natural fibers still account for a major share (some 45%) of the total textile fiber consumption around the world. The term ‘‘manmade’’ applies to all fibers that include those regen- erated from natural products as well as those that are synthesized from basic chemicals. There are a variety of texts dealing with the general classification, properties [4–7], and chemical compositions of textile fibers and the synthesis of manmade fibers [7,8]. In recent years, the original list of manmade fibers has been supplemented by a variety of newly synthesized fibers, engineered specifically for high performance end uses, such as aramid, polysulfide, and polybenzimidazole to name a few. Table 2.2(A) gives the classification of textile fibers [4–9]. Natural fibers are further subdivided into (a) animal, (b) vegetable, and (c) mineral. The fibers from animal sources can be further subdivided into silk, wool, mohair, cashmere, and hair. Vegetable fibers are subdivided into (i) seed fibers (e.g., cotton); (ii) bast fibers (e.g., flax, hemp, jute, and ramie); (iii) leaf fibers (e.g., manila, sisal, and abaca); and (iv) fruit fibers (e.g., coir). Manmade fibers are divided into two main categories, as shown in Table 2.2(B): A. Natural polymer fibers in which the fiber-forming polymer is of natural origin, referred to as regenerated fibers. Copyright © 2004 Marcel Dekker, Inc. Properties of Fibers and Yarns 21 Table 2.2A Classification of Fibers Fiber Natural Manmade (See Table 2.2B) Animal Origin Vegetable Origin Mineral Origin (Asbestos) Silk Wool Hair Seed Origin Bast Origin Leaf Origin Fruit Origin Cotton Flax, Jute, Hemp Sisal, Manila, Henequen Coir Kapok Kenaf, Ramie etc. Abaca, Pineapple Source: Refs. 4–9. Copyright © 2004 Marcel Dekker, Inc. 22 Table 2.2B Classification of Manmade Fibers Manmade Fibers Natural Synthetic Synthetic Polymer Polymer Polymer (from natural origin) Polylactic Acid (PLA fiber) Regenerated Regenerated Celluose Miscellaneous Polyesters Polyamides Polyurethanes Polyvinyl Polymerized Synthetic Polysulfide Polybenzimidazoles Miscellaneous Protein Celluose Esters (alginate, (PET, PBT (nylon 6, (spandex) Derivatives Hydrocarbons Rubber (polyphenylene (PBI) (carbon, (casein, vegetable (viscose, (cellulose natural PCDT, nylon 6.6, (polyethylene, sulfide) metallic, etc.) protein, etc.) cuprammonium) acelate) rubber) etc.) aramids, etc.) polypropylene) Fluorine Chlorine Cyano Hydroxyl Substituted Substituted Substilution Substitution (PTFE) (vinyl alcohol) Monosubstitution Disubstitution Monosubstitution Disubstitution (vinyl chloride (vinylidene (acrylics) (vinylidene & derivatives) chloride) chloride) Source: Refs. 7–9. Copyright © 2004 Marcel Dekker, Inc. Chapter 2 Properties of Fibers and Yarns 23 B. Synthetic fibers in which the fiber-forming material(s) is from basic chemicals. There is now also a new class of synthetic fibers, those produced from material derived from a natural renewable origin, such as corn, known as polylactic acid or polylactide (PLA). Regenerated fibers derived from natural polymers are further subdivided into four groups, namely, a. Cellulose fibers (e.g., viscose, polynosic, cuprammonium rayons, and Tencel or lyocell) b. Protein fibers (e.g., casein) c. Cellulose esters (e.g., acetate and triacetate) d. Miscellaneous fibers (e.g., alginate and natural rubbers) It is more convenient to classify synthetic fibers according to their chemical structure. They fall into the following ten subdivisions: i. Polyurethanes (e.g., Spandex) ii. Polyamide (e.g., nylon 6, nylon 6.6, etc.) iii. Polyesters (e.g., Dacron) iv. Polyvinyl derivatives: a. polytetrafluoroethylene (PTFE) b. polyvinylchloride (PVC) c. polyvinylidene chloride d. polyacrylonitrile (PAN) e. polyvinylidene dinitrile f. polyvinyl alcohol (PVA) g. polystyrene h. miscellaneous polyvinyl derivatives v. Polyolefins (e.g., polyethylene and polypropylene) vi. Polysulfide (e.g., PPS) vii. Aramids (e.g., Kevlar and Nomex) viii. Novoloid (e.g., Kynol) ix. Miscellaneous (e.g., glass, metallic, carbon, and ceramics) x. Polylactic acid or polylactide (PLA) 2.2.2 Essential Properties of Textile Fibers The choice of textile fibers to be used as raw materials in a specific application depends upon a unique combination of different properties. The most essential and desirable properties may be broadly categorized as Copyright © 2004 Marcel Dekker, Inc. 24 Chapter 2 Dimensional or geometric Physical Mechanical General Table 2.3 lists various essential properties of textile fibers. Dimensional